Toroidal coil-winding machine

ABSTRACT

A machine for the winding of toroidal coils enables each turn of the windings to be accurately laid on the core. The machine is controlled by a numerical control system which reads punched tape. The core is held by an adjustable clamp and the clamp is mounted on an indexing wheel which is progressed under control of the tape reader by means of a step motor and an adjustable worm gear.

United States Patent [191 Fahrbach Mar. 26, 1974 TOROIDAL COIL-WINDINGMACHINE [75] Inventor: Rudolf Fahrbach, Branchville, NJ.

[73] Assignee: Universal Manufacturing Company,

Inc., lrvington, NJ.

[22] Filed: Aug. 23, 1971 [21] Appl. No.: 174,104

[52] US. Cl 242/4 B, 242/4 C [51] Int. Cl. HOlf 41/08 [58] Field ofSearch 242/4 R, 4 C, 4 BE, 4 B,

242/DIG. l; 269/63 [56] References Cited UNITED STATES PATENTS 2/1971Fahrbach 242/4 B 1/1965 Foley, Jr. et a1 242/D1G. 1

4/1940 Holleran 242/4 BE 3,383,059 5/1968 Fahrbach.. 242/4 C 3,669,3656/1972 Loturco 242/4 C 2,341,650 2/1944 Quinlan 242/4 C PrimaryExaminer-Billy S. Taylor Attorney, Agent, or Firm-Eliot S.. Gerber [57]ABSTRACT A machine for the winding of toroidal coils enables each turnof the windings to be accurately laid on the core. The machine iscontrolled by a numerical control system which reads punched tape. Thecore is held by an adjustable clamp and the clamp is mounted on anindexing wheel which is progressed under control of the tape reader bymeans of a step motor and an adjustable worm gear.

9 Claims, 8 Drawing Figures PAIENIEB M25 #974 SHEET 1 OF 5 INVEN TOR.fiwou fhmwm Swim PATENIEUHAR26 1974 INVENTOR.

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SHEET a 0F 5 IN VENTOR. i000; fi m/Pena awm '47TOR EY TOROIDALCOIL-WINDING MACHINE BACKGROUND OF THE INVENTION The present inventionrelates to coil winding machines and more particularly to machines toaccurately wind a toroidal coil.

Toroidal coils, in which the turns are accurately positioned on thecore, are useful in various electronic instruments. For example, it isnecessary to precisely locate the turns on a core, possibly withincertain recesses, in the deflection coil of a color television set.

It has been proposed that a suitable coil winding machine may beproduced by using an indexing wheel whose teeth correspond to the turnsto be wound. Such machines, however, sometimes could not be operated athigh speed, without the eventual wear or destruction of teeth of theindex wheel. An improved coil winding machine of this type, using anindex wheel, is shown in the inventors United States Letters Patent No.3,559,899. However, even that improved machine is not entirely flexiblebecause it is necessaryto change the index wheel every time a differentcoil is to be wound.

SUMMARY OF THE INVENTION A toroidal coil (yoke) winding machine isprovided which is controlled by an electronically controlled steppingmotor system which reads a numerical (digital) punched tape. A simplyoperated spring-loaded yoke clamp permits the operator to readily changeyokes. The wire is cut automatically under control of the footagecounter, by an air-cylinder device. The footage counter is resetautomatically when the wire is cut. Separate solenoid operated brakesaccurately position respectively the magazine and the shuttle gear ringof the winding head.

An accurate drive system is provided by a worm gear mounted and fixed ona shaft. The axis of he shaft may be shifted by means of an eccentricarrangement and removably fixed in place. The handle for the shuttlegear ring and the handle for the magazine are aligned along a commonaxis, although each operates independently. An open shuttle magazine isused, saving operator time, which magazine is automatically andaccurately positioned.

These measures decrease to a minimum the steps required for the operatorto wind a yoke, and consequently may speed production. At the same timethey permit different sizes and shapes of cores each to be accuratelywound with very little costly change-over time when changing the size orshape of the core or the spacing of its windings.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings:

FIG. 1 is a perspective over-all view of the coil winding machine of thepresent invention;

FIG. 2 is a side plan view of the clamping mechanism;

FIG. 3 is a side plan view of the worm gear and support for the indextable drive system;

FIG. 4 is a top plan view of the mechanism of FIG.

FIG. 5 is a top plan view of the automatic wire cutter;

FIG. 6 is a side plan view of the braking mechanism;

FIG. 7 is a front plan view of the drive system for the magazine andgear ring and FIG. 8 is a block schematic drawing of the control circuitof the coil winding machine.

The overall control system of the present invention is shown in FIG. 8.As shown, a tape reader 10 reads a punches plastic or paper tape, theholes in the tape representing, in digital form, instructions for themachine. Preferably a standard 8-hole code format is used, a suitablephotoelectric tape reader being available from Superior ElectricCompany. The tape reader 10 receives an input control signal from thephotoelectric pick-up 11 which indicates to the tape reader the passageof the wire. The tape reader 10 is connected to a storage buffer 12,consisting of gates and shift registers, which holds the read code forprocessing. A control signal, on line 12a provides advance and stopsignals to the tape reader 10. The storage buffer 12 provides thecontrol signals, in the form of a parallel word code, to the indexerunit 13, which is a solid state electronic unit which converts theparallel code to serial pulses on three output lines 14, 15, 16, insequence. The three lines 14-16 are connected to stepping motor 17 uponwhose output shaft is mounted a worm gear, described below, to index therotatable table upon whch the core clamp is mounted. A suitable steppingmotor provides 200 steps per revolution and 5 or more revolutions perminute of the head (not the motor), and is also available from SuperiorElectric Co., Connecticut.

The general construction of the machine is shown in FIG. I. As shown, itconsists of a base 20 having a table portion 20a upon which is mounted adrive mechanism 21 having two protruding hand operable handles 22 and23. A fixture 24 is fixed to the rotatable index wheel 24 which isrotatably mounted on dial base'25a. The dial base 25a is fixed on plate25 which is movable, about one inch, toward or away from the front ofthe machine, in the direction of the arrows. The fixture 24, describedbelow, removably holds the core during the winding operation. A seriesof four guide rollers 28, 29, 30, 31 mesh with, and are adapted torotate, a large shuttle gear ring 32. The gear ring 32 has an opensegment, i.e., it is not a complete ring. A magazine 33, also having anopen segment, is similarly supported by four rollers 34, 35, 36, 37which rotate it in one direction to load the magazine and the oppositedirection to wind the coil. An automatic wire cutting mechanism 38 ispositioned upon a platform of the base and the tape reader 10 ispositioned at the top of the base. The photoelectric pick-up 11 consistsof a light emitter 11a which projects alight beam across a gap to aphotoelectric sensor 11b. Every time the wire being wound is pulledthrough the gap, the sensor 11b sends a pulse to the tape reader 10.

The fixture (clamping) mechanism 24 is shown in FIG. 3. A base isadapted to be fixed to the rotatable index table 24a which is fixed torotatable geared wheel 24b, the wheel 24b being below table portion 20a.The wheel 24b meshes with worm 99. An elongated vertically extendingmember 41, integral with or firmly affixed to the base, has an internalbore which is rectangular in cross-section. An elongated slide 42,having a long shank, rectangular in cross-section, slides within thebore. The slide 42, which may have other crosssectional shapes, iselongated to provide an exact holding position to the core and avoid anywobbling. An edge of the slide 42 has gear teeth, forming a rack, whichmesh with the teeth of the pinion gear 43. The

pinion gear 43 is fixed to a shaft 44. A lever 45 is fixed to the piniongear 43. A toggle-like effect is provided by means of a compressiblecoil spring 46. The spring is compressed between a bottom block 47 whichpivots on shaft 48 and a top ring 49. The ring 49 is fixed on shaft 50and shaft 50 slides within the tube 51 fixed to the block 47. The ring49 applies pressure on the cam 52 which is fixed to. the pinion 43.

A bottom bracket 53, which supports the coil, extends horizontally andis fixed to the vertical member 41. A jaw insert 54 is removablyattached to the bracket 53, the effective vertical height of the blocksupport may be changed by changing the jaw insert 54 to one having adifferent height. A locator 55 is removably fixed to the bracket and isused to locate the core by means of a rib or slot at the top of thecore.

A horizontal bracket 56 is fixed to the top of the slide 42. A locatormember 57 is fixed to bracket 56.

In operation, an appropriate locator 55, jaw insert 54 and locatormember 57 are attached to the clamp, depending upon the coil to bewound. Assuming that the slide is up, i.e., the clamp is open, theoperator will place the coil on the jaw insert and locator and lower thelever 45. The spring 46 will push ring 49 to act upon cam 52 to bringdown the slide with its attached arm 57. The arm 57 will descend on thecoil 58 with the correct pressure. The spring 46 serves a doublefunction. As mentioned above, it brings down the slide 42 upon closureand it also keeps the clamp normally open.

FIGS. 3 and 4 illustrate the drive system for the worm gear which mesheswith a gear integral with the revolvable index table upon which the coreclamp is fixed. The stepping motor 17 has an output shaft 78 which isfixed to a joint member 79 having protruding portion 80. The protrudingportion 80 is fixed within a bushing 81. A shaft extension 84 is fixedwithin the joint member 83. The joint members 79 and 83 and bushing 81constitute a universal joint which transmits rotating force from thestepping motor to the shaft 87. The universal joint permits movement ofthe shaft 87 in relationship to the shaft 78 about the pivot axis 85.

The shaft 87 is connected, by means of joint 86, to ball bearings. Shaft87 rotates within two pairs of ball bearings, respectively 88 and 89.The outer races of the ball bearings 88 and 89 are held within a tubularportion 90 integral with the bracket support 91. The bracket support 91is rotatably secured to the table portion of the base by means of thebolt assembly 82. The bracket support 91 is rotatable about the axis 85,the axis of the bolt assembly 82, as well as that of the universaljoint. The bracket support 91 may be clamped securely to the tableportion by means of the bolt assembly 92. A shank 93 of the boltassembly fits within an elongated slot 94 within the bracket support 91so that rotation of the bolt in one direction will clamp the supportagainst the table and rotation in the opposite direction will loosen thebracket support 91 for pivoting motion about axis 85. The shaft 87 isintegral with the worm 99 and an end of the shaft 87 fits within theneedle bearing 100, which bearing 100 is held within a flange 101integral with the support bracket 91. The outer end of the support 91has an enlarged hole 102 through which loosely protrudes the shaft 103of an eccentric mechanism. The shaft 103 has a lower holding member 104below the support bracket 91, an eccentric portion 105 which fits withina cavity 106 of the support bracket 91, and an upper head 107.

The rotation of the head 107 will cause the eccentric to act against theshoulders of the cavity 106, caus ing a shifting movement of the supportbracket 91 about its axis 85. The operator will determine the desiredposition of the worm, push the worm support bracket 91 into the desiredposition by loosening the bolt assembly 92 and turning the head 107 torotate the eccentric 105. When the desired position has been obtained,he will cease rotation of the eccentric 105 and clamp the supportbracket 91 against the table portion by tightening the bolt assembly 92.

FIG. 5 shows the automatic wire cutter. As shown, an air cylinder 110has an output piston shaft 111 which is pivotally connected to a link112 by means of a rod 1 13. The opposite end of the link is fixed to arotatable shaft 113a having an upraised protruding portion 114. A fixedbracket 115 attached to the base has thereon an upraised protrudingportion 1 16 which is fixed. The air cylinder 110 is operated from asource of air pressure (not shown) and is controlled by means of anelectrically operated valve which receives its control signals from thewire footage counter. Upon receiving a control signal to cut the wire117 the shaft 111 will be retracted, thereby rotating the link 112 in acounterclockwise direction. Such counterclockwise motion of the link 112causes the protrusion 114 to move counterclockwise and cut the wire 117which is between the nose 1 18 of the protrusion 1 14 and the fixedprotrusion 1 16. The wire footage counter is automatically reset at zeroby the same signal that causes the wire to be cut.

A preferred brake mechanism to exactly stop the rotation of the magazinein its desired position is shown in FIG. 6. The same type of brakemechanism, but a second unit, is used to brake the gear ring. A solenoid120, or alternatively, an air operatied cylinder, is mounted on abracket 121 fixed to the base. The solenoid receives its control signalsfrom a photoelectric pick-up which, in turn, is informed of the positionof the gear and magazine by means of a synchronized gear train. Twosmall gear trains (not shown) each mesh with the respective gearsdriving the magazine and gear ring. A gear in each gear ring rotates atthe same speed relative position as the respective magazine and gearring. Each of the two synchronized gears has a hole which may be alignedwith a light beam produced by a light emitter and detected by aphotoelectric sensor. When the hole is aligned with the beam, the sensorproduces a control pulse to the solenoid, or air cylinder, braking themagazine or gear ring and correctly positioning them. The output shaft122 of the solenoid is connected, by means of connection member 123, toa flexible strap 124. The opposite end of strap 124 is held fixed in aclamp 125, the clamp 125 being pivotly fixed to a support member affixedto the base. A shoulder of the drive gear 126 for the gear or magazinefits within the curve of the flexible strap 124. Preferably the strap124, on its face towards the drive gear of the magazine, has a highlyfrictional material, for example, the strap may be of steel. Uponreceipt of a braking control signal, the solenoid 120 will pull in theoutput shaft 122, causing the strap 124 to brake the motion of the drivegear for the magazine.

The driving gear system for the magazine and the shuttle gear ring isshown in FIG. 7. It has two handles 23 and 22 which are aligned along acommon axis but are completely independent of each other. Rotation ofhandle 22 by the operator will not move handle 23 and its associatedgearing, nor will rotation by the operator of the handle 23 turn thehandle 22 and its associated gearing. The handle 22 turns the shuttlegear ring 32 and the handle 23 turns the magazine 33.

The handle 22 is fixed to a shaft 130 which is rotatable withinthesupport portion 131 which is part of the casing of the winding headdrive mechanism 21. A pulley 132 is fixed to the shaft 130. A timingbelt operatively connects the pulley 132 to an electric motor. The shaft130 is also connected to the ring drive gear 133. A rim 134 of the ringdrive gear is used for braking, by means of the solenoid operated strap,as described above. The ring drive gear meshes with two shuttle gearring idlers, 135 and 136, shown in FIG. 7. The shuttle gear ring idlers135, 136 and ring drive gear 133 mesh with and rotate the shuttle gearring.

The handle 23 is fixed to a shaft 140 which rotates within the supportportion 141 of the drive mechanism 21. A pulley 142 is fixed to theshaft 140 and a belt 142a operatively connects the pulley 142 with anair motor. The air motor winds the wire in the magazine (in onedirection of rotation of the magazine) and provides some brakingresistance during the wire winding operation (in the opposite directionof rotation of the magazine). The magazine drive gear 143 is fixed tothe shaft 140 and has a rim 144 upon which is positioned a brake band145. The brake band 145 is preferably of the same type of mechanism asdescribed above, using a steel strap which may be pulled taut by asolenoid. The magazine drive gear 143 is connected to two magazine idlergears, 146 and 147, shown in FIG. 7. The magazine idler gears 146 and147 are carried by bearings which rotate on, respectively, shafts 148and 149. The shafts 148 and 149 also carry the bearings for the shuttlegear idlers. However, there are no operative connections between theshuttle gear idlers and the magazine idler gears, as each rotatesindependently on the same shaft.

I claim:

1. A toroidal coil winding machine including a base, motor meanspositioned on the base, a magazine adapted to be loaded with wire androtated by said motor means, a clamp adapted to hold a core for winding,an index table upon which said clamp is mounted and which is rotatablymounted relative to said base; a worm wheel fixed to said index table; astepping motor operatively connected to a worm mounted on a shaftrotatably held in a bracket pivotally mounted on said base and rotatablymounting said worm gear shaft, said worm meshing with said worm wheel;and a universal joint operatively connecting said worm shaft and theshaft of said stepping motor.

2. A toroidal coil winding machine as in claim 1 wherein said bracket isremovably fixed to said base by a fixing means, said bracket is mountedto move about an axis, and said bracket may be shifted about its axis byan eccentric mechanism.

3. A toroidal coil winding machine including a base, motor meanspositioned on the base, a magazine adapted to be loaded with wire androtated by said motor means, a rotatable clamp adapted to hold a corefor winding, in combination:

an index table upon which said clamp is mounted and which is rotatablymounted relative to said base, a gear connected with said index table; 1

a stepping motor operatively connected to a gear system and said gearsystem being operatively connected to said index table;

said gear system including a worm gear mounted on a shaft, pivotablebracket means to rotatably support said worm gear shaft, and a universaljoint operatively connecting said worm gear shaft and the shaft of saidstepping motor, said worm gear meshing with said gear connected withsaid index table;

a numerical control and tape reader system connected to said steppingmotor to provide control signals to said motor; and

a pick-up system connected to said control system and positioned on saidbase to monitor the wire being wound and to provide control signals tosaid control system.

4. A toroidal coil winding machine as in claim 3 wherein said controlsystem includes a tape reader, a storage buffer, and an indexer unitwhich produces pulses to said stepping motor on a plurality of lines.

5. A toroidal coil winding machine as in claim 3 and also including anautomatic wire cutter mounted on said base, said wire cutter comprisingmotor means, a rotatable cutter connected to said motor means and afixed cutter member secured to said base.

6. A toroidal coil machine as in claim 3 and further including pivotmeans to mount said bracket to said base so that said bracket ispivotable about an axis, and an eccentric mechanism operable betweensaid bracket and said base to selectively pivot said bracket.

7. A toroidal coil machine as in claim 1 and further including pivotmeans to mount said bracket to said base so that said bracket ispivotable about an axis, and an eccentric mechanism operable betweensaid bracket and said base to selectively pivot said bracket.

8. A toroidal coil winding machine as in claim 3 wherein the pivotcenter of said pivotable bracket and the pivotable center of saiduniversal joint are vertically aligned.

9. A toroidal coil winding machine as in claim 1 wherein a plurality ofidler rollers support and rotate said magazine and the machine furtherincludes a magazine drive gear meshing with said idler rollers, a handlefixed to the shaft of said magazine driver gear, connection motor meansto selectively rotate said magazine drive gear;

a rotatable gear ring, a plurality of idler gear ring rollers meshingwith and adapted to rotate said gear ring, a gear ring drive gearmeshing with and driving said idler gear ring rollers, and a secondhandle fixed to the shaft of said gear ring drive gear,

wherein the shafts of said magazine drive gear and said gear ring drivegear lie along a common axis and those shafts are not operativelyconnected.

1. A toroidal coil winding machine including a base, motor meanspositioned on the base, a magazine adapted to be loaded with wire androtated by said motor means, a clamp adapted to hold a core for winding,an index table upon which said clamp is mounted and which is rotatablymounted relative to said base; a worm wheel fixed to said index table; astepping motor operatively connected to a worm mounted on a shaftrotatably held in a bracket pivotally mounted on said base and rotatablymounting said worm gear shaft, said worm meshing with said worm wheel;and a universal joint operatively connecting said worm shaft and theshaft of said stepping motor.
 2. A toroidal coil winding machine as inclaim 1 wherein said bracket is removably fixed to said base by a fixingmeans, said bracket is mounted to move about an axis, and said bracketmay be shifted about its axis by an eccentric mechanism.
 3. A toroidalcoil winding machine including a base, motor means positioned on thebase, a magazine adapted to be loaded with wire and rotated by saidmotor means, a rotatable clamp adapted to hold a core for winding, incombination: an index table upon which said clamp is mounted and whichis rotatably mounted relative to said base, a gear connected with saidindex table; a stepping motor operatively connected to a gear system andsaid gear system being operatively connected to said index table; saidgear system including a worm gear mounted on a shaft, pivotable bracketmeans to rotatably support said worm gear shaft, and a universal jointoperatively connecting said worm gear shaft and the shaft of saidstepping motor, said worm gear meshing with said gear connected withsaid index table; a numerical control and tape reader system connectedto said stepping motor to provide control signals to said motor; and apick-up system connected to said control system and positioned on saidbase to monitor the wire being wound and to provide control signals tosaid control system.
 4. A toroidal coil winding machine as in claim 3wherein said control system includes a tape reader, a storage buffer,and an indexer unit which produces pulses to said stepping motor on aplurality of lines.
 5. A toroidal coil winding machine as in claim 3 andalso including an automatic wire cutter mounted on said base, said wirecutter comprising motor means, a rotatable cutter connected to saidmotor means and a fixed cutter member secured to said base.
 6. Atoroidal coil machine as in claim 3 and further including pivot means tomount said bracket to said base so that said bracket is pivotable aboutan axis, and an eccentric mechanism operable between said bracket andsaid base to selectively pivot said bracket.
 7. A toroidal coil machineas in claim 1 and further including pivot means to mount said bracket tosaid base so that said bracket is pivotable about an axis, and aneccentric mechanism operable between said bracket and said base toselectively pivot said bracket.
 8. A toroidal coil winding machine as inclaim 3 wherein the pivot center of said pivotablE bracket and thepivotable center of said universal joint are vertically aligned.
 9. Atoroidal coil winding machine as in claim 1 wherein a plurality of idlerrollers support and rotate said magazine and the machine furtherincludes a magazine drive gear meshing with said idler rollers, a handlefixed to the shaft of said magazine driver gear, connection motor meansto selectively rotate said magazine drive gear; a rotatable gear ring, aplurality of idler gear ring rollers meshing with and adapted to rotatesaid gear ring, a gear ring drive gear meshing with and driving saididler gear ring rollers, and a second handle fixed to the shaft of saidgear ring drive gear, wherein the shafts of said magazine drive gear andsaid gear ring drive gear lie along a common axis and those shafts arenot operatively connected.